Insulated double and triple glazed units, custom-built to specification and manufactured to the highest standards

Insulated glass units

CI/SfB | (31.4) | Ro

The Global Glass specialist manufacturing and supply division has been established to expand Synseal operations beyond core PVC-U extrusion activities with the ability to provide high quality sealed insulated glass units to fabricator partners that are optimised to deliver the best possible thermal efficiency when used in combination with the company’s proven conservatory roof and PVC-U window and door systems.

With plants in three strategic locations, Global Glass has

grown steadily and is now one of the Top 10 volume IGU

makers in the UK today, manufacturing in excess of 4,000

IGUs per day.

Global Glass offers a highly focussed range which principally

caters for volume demand, majoring on 28mm double

glazed units and also supplying triple glazed units built to

specification, as and when required. Variations of spacer

bar (warm edge spacer, aluminium spacer and warm edge

super spacer) and Clear, Blue, Aqua and Bronze colours are

available, together with decorative glass solutions, Argon or

Krypton gas-filling and Low-E and low maintenance glass

coating options.

The exclusive Celsius premium performance glass delivers

added value in both commercial and retail market arenas

and is a key differentiator for Global Glass.

Three efficient IGU manufacturing plants

In November 2011 Global Glass was created when a local

Nottinghamshire sealed unit maker Midland Glass Supplies,

was acquired by Synseal. Initial operations at Global Glass

Huthwaite focussed on toughened roof glass, sold in

combination with the UK’s best-selling Global conservatory

roof to provide an efficient service to customers for Global

roof kits, including made to measure high performance roof

glass units. Global Glass Huthwaite is now Synseal’s prime

manufacturing facility for window and door IGUs.

In May 2012, a second glass plant was added with the

acquisition of K2 Conservatories to create Global Glass

Blackburn, which boasts well-established glass unit

manufacturing operations and a unique premium product

offering in the shape of Celsius performance glass.

The exclusive Celsius range offers three formulations:

In July 2014 a third glass plant was added with the

acquisition of the business and assets of Prospect Inc. Ltd,

trading as Systems Glass, to create Global Glass Wigan.

Located at Challenge Way in Wigan with convenient access

to both the M6 and M58 motorways, this facility supplies

quality products which include insulated glass units for

window frame and roof applications as well as quantities of

single sheet toughened glass.

Global Glass - a specialist supplier

is Synseal’s No.1 IGU manufacturing plant in volume output terms. Our Huthwaite plant builds and despatches many thousands of high quality sealed units every single day.

is now Synseal’s centre of excellence for roof glass, enabling Global Glass Huthwaite to concentrate on producing window and door glass in volume.

has an existing capacity of 9,000 window and door glass IGUs per week which will be increased further through additional Synseal investments to fully maximise the potential of this spacious site.

ideal for conservatory window frames

with a centre pane U-value of 1.0 W/m2K

an effective roof glass specification with

a centre pane U-value of 1.0 W/m2K

the ultimate roof glass specification with

a centre pane U-value of 0.9 W/m2K

huthwaite blackburn wigan

Looking to the future

Investment for growth

In the UK glazing industry it is widely accepted that

the average market quality control reject rate for

sealed glass units is 2.5%, however Global Glass

achieves a low reject rate of just 1% for window glass

and 1.5% for roof glass.

Continued investment is crucial to maintain and

improve product quality and customer service

standards and meet the strong demand for

high quality IGUs from Synseal’s trade fabricator

and installer customer base. Recent business

improvements include:

• New toughening furnace and glass handling

equipment at Global Glass Huthwaite

• New furnace, IGU line and arrissing equipment to

almost double capacity at Global Glass Blackburn

• New cutting table at Global Glass Wigan

• New production layout improvements at Global

Glass Wigan are ongoing to maximise the

potential of the plant

• New order optimisation batching and delivery

vehicle scheduling procedures

• New purpose-built delivery stillages to reduce

breakages in transit

• New manufacturing plant loading procedures to

eliminate double handling

• New edge protectors and banding of units to

eradicate potential damage when loading

• New invoicing system with improved unit

identification to consolidate despatched items

• Electronic data interfaces (EDI links) with major

customer accounts, to speed order processing

and maximise efficiency

Producing quality units every time

The perfect glazing solution

Global Glass system guide | 3

Global Glass - superior quality built-in

Global Glass is a specialist manufacturing division of Synseal Extrusions Ltd. Specify Global Glass to ensure the very best in product quality and service.

Total quality control is carried out using two basic principles:

building-in quality at every stage and continually improving

quality standards in order to achieve optimum performance

and customer satisfaction.

Insulated glass unit (IGU) manufacturing for windows, doors

and conservatories is all undertaken on-site at a specialist

Global Glass plants located in Huthwaite, Nottinghamshire

and Blackburn and Wigan in Lancashire. This ensures

quality control of manufactured products, stock, cost base

management, reliability of supply chain materials and, even

more importantly for customers, precise management of

price, lead times and product availability.

The IGU assembly process is automated and testing is

computerised to ensure a consistently high quality product.

With investment in the latest technologies and modern

machinery, Global Glass delivers products which are

consistent in quality.

Operational processes are constantly reviewed to reduce

waste, diagnose potential problems and identify solutions

quickly and systematically.

The Global Glass team continually works towards improving

quality management practices to:

• Achieve and improve customer satisfaction

• Improve and innovate working methods

• Increase efficiency and reduce both waste and cost

• Ensure high levels of corporate care and responsibility

New purpose built glass stillages Toughening furnace at Huthwaite

Global Glass operates state of the art dedicated double and triple glazing lines to ensure maximum efficiency

Global Glass system guide | 5

Double glazed units

Double glazed sealed unit construction options are

aluminium spacer bar, warm-edge spacer bar or a

warm-edge super spacer bar (which is ideal for

non-rectangular roof glass), with either 2 part or butyl

hot-melt secondary seals depending on specification.

Vertical sliding sash windows are typically glazed

with 24mm DG units (4:16:4). Domestic specification

casement windows/doors and conservatory roofs are

typically glazed with 28mm DG units (generally 4:20:4,

although a range of pane and airgap configurations

are available including 6:16:6 and 6:18:4).

Triple glazed units

Triple glazed sealed unit construction options are

aluminium spacer bar, warm-edge spacer bar or a

warm-edge super spacer bar, with either 2 part or

butyl hot-melt secondary seals depending

on specification.

Domestic specification casement windows/doors can

be optionally glazed with 36mm TG units (4:12:4:12:4)

or 40mm TG units (4:14:4:14:4), according to the

system specified.

Choosing a sealed glass unit manufacturer is a critical decision. Consumers are increasingly demanding higher energy ratings to keep their homes warmer and heating bills lower.

Combining energy efficient frames and glass is crucial to

delivering overall window thermal performance. Whether

the BFRC Window Energy Rating scheme or FENSA U-value

rating is selected as the route to technical compliance,

Global Glass is the supplier of choice for thermally efficient

sealed units. Whatever the rating required, Global Glass has

the IGU products to meet energy efficiency needs. With

Argon or Krypton glass-filled cavities and warm edge spacer

bar options, Global Glass can deliver a range of thermal

performance solutions to satisfy customer requirements.

Global Glass employs a continuous improvement policy to

ensure that both manufacturing technology and production

standards are optimised.

This policy has already seen investment in state-of-the-art

gas filling technology, improved toughening facilities,

inspection systems and logistics. Further strategic

investments in both technology and processes will be

deployed as Global Glass intends to lead the way in

advanced glass manufacturing technology.

Global Glass constantly strives to find new ways to design,

produce and deliver market leading IGU products.

Insulated glass units

The Global Glass range of low maintenance and solar control glasses are a perfect choice for customers looking for the ultimate in glass solutions.

Low maintenance glass

A revolutionary low maintenance coating is applied to the

glass as part of the manufacturing process, which means

that it is fused to the surface of the glass and therefore

lasts the lifetime of the pane. The coating uses the rain and

natural light from the sun to efficiently combat the dirt and

grime that accumulates on the outside of the window. By

reducing the need for manual cleaning, low maintenance

glass provides an ideal and safe solution for keeping hard

to reach or hazardous glazed surfaces clean.

How does it work? There are two processes. Firstly, the

special coating harnesses the natural daylight which triggers

the breakdown of the dirt and grime on the outside of the

glass and secondly, when the rainwater hits the glass, rather

than forming droplets, it flattens and spreads out across the

surface of the glass helping to wash away the dirt and grime.

This sheeting effect also minimises spots and streaks by

helping the glass to dry more quickly and evenly.

Normal glass Low maintenance glass

Solar control glass

Solar ccontrol coated glass can be used on windows, doors

and most commonly on conservatory roofs to help prevent

the build-up of heat during the hot summer months.

The coating on the glass helps reflect heat from the sun

back to the outside atmosphere, giving a more comfortable

and useable living space. The glass is available in a range of

tints which allows the glass to absorb more heat, whilst the

coating reflects heat back to the outside.

• Solar coating reflects heat back to the outside

• Tinted glass absorbs heat

• Tint and coating together both absorbs and

reflects heat for maximum comfort

Low-E glass

Low-E glass has a microscopic metal coating which reflects

central heating back into the room. DG units incorporating

this specially coated glass offer up to 33% better insulation

than conventional insulated glass units, to keep homes

warmer and reduce heating bills.

Global Glass - custom-made to project specifications

Global Glass can supply a wide range of colours and

coatings to suit each project, including clear and patterned

glass types, Low-E glass in a range of tinted colours, low

maintenance glass and Argon or Krypton gas-filled options.

• Permanent low maintenance coating lasts

the lifetime of the window

• Perfect for areas that are hard to clean

• Glass stays cleaner for longer

• Less dirt and grime adheres to the window,

so any cleaning is quick and easy

• Reduced window cleaning costs

• Less frequent use of cleaning materials,

so kinder on the environment

• Available in a range of tint colours

Clear glass Blue Aqua Bronze

Low maintenance, solar control & Low-E glass coatings

Global Glass system guide | 7

Spacer bars

Dividing glass panes in a sealed DG or TG unit, the spacer

bar is bonded to glass panes creating an airtight cavity

which is then filled with air or gas, as specified. To prevent

condensation the spacer bar is filled with a desiccant to

absorb any moisture. The spacer bars are manufactured

from either aluminium or a low heat conductive material

and are important in the achievement of energy ratings.

Global Glass offers a choice of:

Window Energy Ratings

Window Energy Ratings (WER) are design simulations that

can accurately calculate how energy-efficient a specified

window will be in use. The WER system is based on a scale of

A-G, with A-rated windows being the most energy-efficient.

Up to 25% of heat within homes escapes through windows,

so consumers are increasingly demanding A-rated windows

to retain domestic heat and lower energy bills.

A Window Energy Rating and label applies to a whole

window (frame and glass) rather than the frame or

glass components individually. A combination of multi-

chambered PVC-U window frame profile, spacer bar and

high performance glass will create the most thermally-

efficient project solution. Door Set Energy Rating (DSER)

calculations provide similar thermal evaluations for doors.

Synseal can provide expert advice to assist in all aspects of

WER and DSER specification, with simulations carried out in

accordance with BS EN ISO10077-2.

Energy efficiency

Aluminium spacer bars

• Durable • Light • Flexible

Warm-edge spacer bars

• Thermal performance • Reduce condensation

Warm-edge super spacer bars

• Thermal performance • Reduce condensation

• Highly pliable for shaped glass panes

Gas filling

Air currents between sealed

IGU glass panes carry heat

to the top of the unit and

settle into cold pools at

the bottom. Filling this

airgap space with a less

conductive, more viscous, or

slow-moving gas minimizes

the convection currents

within the space, reduces

conduction through the gas and the overall transfer of heat

between the inside and outside is reduced.

Global Glass offer Argon and Krypton gas fills, with

measurable improvement in thermal performance. Argon is

inexpensive, non-toxic, non-reactive, clear, and odourless.

Krypton is non-toxic, non-reactive, clear, and odourless

and delivers better thermal performance than Argon, but

is more expensive. Krypton gas filling is particularly useful

when slimline, high-performance bespoke sealed units with

smaller airgaps are required.

Celsius Performance Glass

The exclusive Celsius range is suitable for residential and commercial installations and supplied in three formulations: Celsius One, Celsius Elite and Celsius Clear. An easy clean ‘non-stick’ coating is standard across the range and reduces cleaning maintenance by up to 70%.

Celsius One and Celsius Elite reflect approximately 3 times

more solar energy than standard glass and deliver superior

levels of UV protection. The blue tinted coating applied

to Celsius One and Celsius Elite units significantly reduces

visible light transmission, to soften the impact of natural

light passing through a conservatory roof and increase

homeowner comfort.

Celsius Clear maximises natural light with a visible light

transmission of 61%. This neutral tinted glass is ideal for the

side of window frames of a conservatory, or north-facing

conservatory roofs that need to allow in more warmth during

winter while still offering suitable heat reflection during the

summer months.

Mobile demonstration unitsThe unrivalled thermal performance of Celsius performance

glass compared to standard specification double glazing can

be clearly demonstrated using Synseal’s mobile heat lamp

retail demo units, enabling UK homeowners to literally

‘feel the difference’.

Certificate of AuthenticityCelsius toughened roof glass units

and clear glass units for conservatory

window walling are specially

processed, stamped and protected

with an itemised ‘Certificate of

Authenticity’ to enable UK consumers

to register their genuine Celsius

installations online and receive 10

year enhanced warranty benefits for

added peace of mind.

Celsius performance glass sealed units are constructed using various layers/components, as illustrated. Please note these visuals are for illustration purposes only and do not represent exact thickness scales. Colours shown are not indicative of actual glass colouring.

Manufacturing standardsThe Celsius range carries the BS EN 1279-2

and BS EN 12150-1 standards and is backed

by a 10-year warranty against seal failure.

EASY CLEAN COATINGCELSIUS TOUGHENED GLASSSOLAR CONTROL COATINGLOW E COATING

ARGON GASCLEAR TOUGHENED GLASS

BLUE TINT EASY CLEAN COATINGCELSIUS TOUGHENED GLASSSOLAR CONTROL COATINGLOW E COATING

ARGON GASLOW E COATINGCLEAR TOUGHENED GLASS

BLUE TINT EASY CLEAN COATINGCELSIUS TOUGHENED GLASSSOLAR CONTROL COATINGLOW E COATING

ARGON GASCLEAR TOUGHENED GLASS

CLEAR

Celsius Performance Glass utilises a Low-E and solar control combination coating, with an Argon filled cavity, to control the amount of visible light, UV and heat that pass through the glazed unit. Easy Clean technology has also been added to reduce maintenance requirements.

StandardGlass

25mmPolycarbonate

U-value 2.8 1.6 1.0 0.9 1.0

Solar factor 75% 55% 22% 22% 42%

Visible light transmission 80% 68% 38% 34% 61%

Heat reflection 25% 45% 78% 78% 58%

UV protection 25% 45% (bronze) 94% 94% 73%

Toughened to BS EN 12150-1 3 7 3 3 3

Manufactured to BS EN 1279-2 3 7 3 3 3

10 year warranty against seal failure 3 7 3 3 3

Easy clean coating 7 7 3 3 3

Cavity fill Air 7 Argon Argon Argon

Tinted 7 7 Blue tint Blue tint Neutral tint

The at-a-glance comparison figures shown are for guidance purposes only. Slight variations may occur due to glass specification, time of year, manufacturing tolerance, point of manufacture and type of instrumentation used.

Solar Factor: The percentage of total energy (heat) from the sun which is able to pass through the glass.Visible Light Transmission: The percentage of visible light which is directly transmitted through the glass.UV Protection: The percentage of damaging UV rays from the sun which is unable to pass through the glass.

Global Summer interior finished in Chartwell Green with Celsius Elite high performance glass

Global Glass system guide | 9

The glass market is forever changing with new technologies,

standards and regulations affecting the industry. At Global

Glass an experienced and skilled customer care team is

always on hand to provide technical advice, address any

glass-related questions and assist with project enquiries.

The sub-sections of Building Regulations Part L refer to

different building types and itemise U-value thermal

performance. Standards for refurbishment of existing

buildings are more exacting and provide options for using

WER ‘whole unit’ calculations in place of the established

U-values.

*Option of WER band C or better. •Option of WER band C or 1.6 W/m2K for buildings essentially domestic in character (e.g. student accommodation).

Reference document BRE 443 provides U-value specification guidance for non-vertical glazed surfaces.

Technical support

Part L Building application U-value

L1A New dwellings 2.0 W/m2K

L1B Existing dwellings 1.6 W/m2K*

L2A New buildings other than dwellings 2.2 W/m2K

L2B Existing buildings other than dwellings 1.8 W/m2K•

Part L requirements for windows, roof windows, rooflights, curtain walling and pedestrian doors

Quality

All Global Glass sealed IGU products carry a 10 year

guarantee against failure and are produced in accordance

with BS EN 1279-2, BS EN 1279-3 and BS EN 12150-1 under

strict quality control procedures to ensure consistency and

precision of manufacture, each and every time.

Products undergo a wide range of QC inspections during

and after the production process. All equipment is

thoroughly checked and maintenance schedules are

strictly adhered to.

Conservatory roof glass High performance window IGUs

Global Glass provides tailored solutions ideal for both commercial and residential applications

Automated glass cutting table

Global Glass system guide | 11

Synseal’s main site and production centre at Huthwaite

Automated arrissing line

IGU line at Blackburn

Synseal’s delivery vehicles are specially equipped for glass transportation

Decorative glass manufacturing

ZMG

G/T

ECH

NIC

AL

v3 Global Glass Huthwaite | 28b Nunn Brook Road | Huthwaite | Nottinghamshire | NG17 2HU | Tel 01623 446303 | Fax 01623 550173

Global Glass Blackburn | Century House | Roman Road | Blackburn | Lancashire | BB1 2LD | Tel 01254 683000 | Fax 01254 683146

Global Glass Wigan | Challenge Way | Wigan | Lancashire | WN5 0LD | Tel 01924 211197 | Fax 01942 211206

Global Glass is a specialist manufacturing division of Synseal Extrusions Ltd. Established over 30 years ago, Synseal now employs over 1200 people and has a turnover in excess of £130 million. Main operations are located at a UK-based 35 acre site with 70,000 square metres of production, warehousing and office facilities.

The corporate objective at Synseal is to deliver thermally

efficient products of consistently excellent quality and

design to markets worldwide, at competitive prices.

Synseal constantly seeks to develop environmentally

friendly new products which will support sustainable

development and reduce carbon consumption. New

ranges are designed with 100% recyclability, improved

performance and cost-effectiveness in mind.

Synseal is ISO14001 accredited which ensures that all

company environmental management systems comply

with and even exceed government mandates.

All quality management systems are ISO9001 accredited

which ensures that all processes are constantly checked and

improved upon, to reduce waste and increase efficiency.

Synseal products are independently tested and accredited

by the British Standards Institute (BSI) and the British Board

of Agrément (BBA).

Synseal is a leading UK manufacturer of conservatory roof, window and door systems

ISO14001Environmental management accreditation

ISO9001Quality systems

accreditation

BBAConstruction

industry accreditation